Safety valve and method of use

ABSTRACT

Embodiments of a method of operating a safety valve and a safety valve system are provided. The valve system includes a valve, an actuator, a mechanical override, and an indicator. The actuator includes a fail-safe mechanism and the indicator is configured to indicate whether the fail-safe mechanism is operable during use of at least one of the actuator and the mechanical override. In one embodiment, a method of operating the safety valve includes actuating the valve into an open position and sending a signal to indicate that the fail-safe mechanism is operable to move the valve to the closed position, while the valve is in the open position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/073,609, filed Mar. 28, 2011, which claims benefit of U.S.Provisional Patent Application Ser. No. 61/319,697, filed Mar. 31, 2010,and U.S. Provisional Patent Application Ser. No. 61/356,506, filed Jun.18, 2010, which applications are herein incorporated by reference intheir entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention generally relate to a safety valve. Moreparticularly, embodiments of the invention relate to a safe modeindication device for a safety valve actuator.

2. Description of the Related Art

Various designs of valve actuators exist that operate to open and closevalves in a variety of uses. The petroleum industry utilizes theseactuators to operate gate valves that incorporate a sliding gate withina valve body to selectively block fluid flow through tubing. Positioninggate valves along tubing at various locations controls and directs theflow of fluids through the tubing. An assembly known as a christmas treeincludes these valves along with spools, pressure gauges, fittings,and/or chokes connected to the top of a well in order to direct andcontrol the flow of formation fluids or production fluids from the well.

In operation, a valve stem extending from the valve body of the gatevalve moves axially within the valve body in order to move the slidinggate between an open position and a closed position. A shaft within anactuator for the gate valve engages the valve stem to impart the axialmovement to the valve stem. Typically, the actuator includes a spring tobias the shaft within the actuator such that the gate valve provides afail-safe to the closed position. In this manner, force applied to theshaft of the actuator from either a hydraulic, pneumatic, or mechanicalsource, depending on the type of actuator, overcomes the bias of thespring to move the sliding gate to the open position. Other gate valvedesigns provide for the fail-safe in the open position or afail-in-position which maintains the position of the sliding gate uponfailure. If the shaft or a top shaft coupled to the shaft extendsexternal to the actuator, the amount of the shaft extending from theactuator may serve as a visual indication as to whether the valve is inthe open position or the closed position.

The actuators commonly used to open and close the gate valves includemechanical overrides that use a mechanical force, automatic actuatorssuch as various designs of pneumatic or hydraulic actuators, orcombination actuators having both a mechanical override and an automaticactuator. Since most automatic operations of the actuators have amaximum capability for applying force to the valve stem, the combinationactuator permits additional opening/closing power on a temporary basiswithout having to remove the original automatic actuator. Inadvertentloss of pneumatic or hydraulic pressure to the automatic actuator closesthe gate valve which can interrupt production and interfere withwellbore completion operations occurring through the valve. Thecombination actuator provides a back-up for automatic operation, allowsfor testing, and enables an operator to lock the valve in the openposition using a handwheel assembly of the mechanical override duringvarious wellbore completion operations.

The combination actuators described above, however, fail to provide avisual indication whether the valve has been actuated using themechanical override, the automatic actuation, or both. Although theshaft extending from the valve may in some cases provide a visualindication that the valve is either open or closed, the visualindication does not communicate which actuation mechanism is being usedto position the valve in the open or closed position or whether thevalve is fully open or fully closed. The lack of this communication canbe detrimental in various situations. For example, a valve operator maybelieve that a valve having a fail-safe closed mechanism has beenautomatically actuated into an open position, when in fact the valve mayhave been opened using the mechanical override. Since the mechanicaloverride may also override the fail-safe closed mechanism, the operatoris thus under the mistaken belief that the valve is operating in a safemode. In the event of a shut-down, the valve will remain locked open andbe prevented from failing or moving into the closed position. In anotherexample, when using the mechanical override, it is critical that thehandwheel assembly is completely rotated until the valve is fully openor fully closed. Only a few turns of the handwheel can offset the valvegate, and yet the appearance of the handwheel shaft extending from theactuator cannot communicate this slight offset. Thus when automaticoperation occurs, the valve cannot be situated in a fully open or fullyclosed position, potentially causing leakage in the valve and un-evenwear of the valve's seat and/or seals of the gate or body by fluid flowthrough the slightly offset valve.

Thus, there exists a need for an improved mechanical override for usewith an actuator for a valve. There exists a further need for a valvehaving a mechanical override that provides a visual indication of thestatus and/or position of the valve, as well as which actuationmechanism is operating the valve, when the valve is operating in a safemode, and/or when the mechanical override is intervening with thefail-safe mechanism.

SUMMARY OF THE INVENTION

Embodiments of the invention include a valve system. The valve systemmay comprise a valve, an actuator, a mechanical override, and anindicator. The actuator may include a fail-safe mechanism and may beconfigured to actuate the valve using fluid pressure. The mechanicaloverride may be configured to actuate the valve using mechanical forceand to override the fail-safe mechanism. The indicator may be configuredto indicate whether the fail-safe mechanism is operable during use of atleast one of the actuator and the mechanical override.

In one embodiment, a valve system may comprise a valve, an actuator, andan indicator. The actuator may include a fail-safe mechanism and may beoperable to actuate the valve to an open position and a closed position.The indicator may be operable to indicate that the valve is movable tothe closed position using the fail-safe mechanism when the valve is inthe open position.

In one embodiment, a method of operating a valve may comprise providinga system having a valve, an actuator, a mechanical override, and anindicator. The actuator and the mechanical override may be operable toactuate the valve to an open position and a closed position. The methodmay include actuating the valve into the open position using theactuator, and sending a signal to indicate that the actuator is operableto move the valve to the closed position, while the valve is in the openposition.

In one embodiment, an apparatus may comprise a housing having a boredisposed therethrough; a piston movable within the housing; a pistonseal positioned between the piston and the housing and movable relativeto the piston or the housing; a biasing member operable to move thepiston within the housing to a first position; and a contact memberoperable to move the piston seal within the housing to a second positionagainst the bias of the biasing member. The piston seal forms a sealwith the piston and an inner surface of the bore when in the firstposition. The piston seal does not form a seal with the piston and theinner surface of the bore when in the second position.

In one embodiment, an indicator apparatus may comprise a housing havinga bore disposed therethrough; a piston movable within the housing; abiasing member operable to move the piston to a first position; acontact member operable to move the piston to a second position againstthe bias of the biasing member; and an indicator coupled to the piston,wherein the indicator provides a signal viewable through an opening inthe housing when the piston is moved to the first position and adifferent signal viewable through the opening when the piston is movedto the second position.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the inventioncan be understood in detail, a more particular description of theinvention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 is a sectional view of a gate valve, an actuator, a mechanicaloverride, and a safe mode indicator according to one embodiment.

FIG. 2 is a sectional view of the gate valve in an open position after amanual operation of the mechanical override.

FIG. 3 is a sectional view of the gate valve in the open position afteran automatic operation of the actuator and with the safe mode indicatorindicating that the gate valve is operating in a safe mode.

FIG. 4 is a sectional view of the gate valve in the open position afterthe automatic operation of the actuator, the mechanical override havingbeen partially actuated, and the safe mode indicator indicating that thegate valve is not operating in the safe mode.

FIG. 5 is a cross-sectional view of the mechanical override alongsection line 5-5 in FIG. 1.

FIG. 6 is a sectional view of the gate valve in an open position afteran automatic operation of the actuator.

FIGS. 7A and 7B are sectional views of a safe mode indicator accordingto one embodiment.

FIG. 8 is a sectional view of a gate valve, an actuator, a mechanicaloverride, and a safe mode indicator according to one embodiment.

FIG. 9 is a sectional view of the gate valve in an open position after amanual operation of the mechanical override.

FIG. 10 is a sectional view of the gate valve in the open position afteran automatic operation of the actuator and with the safe mode indicatorindicating that the gate valve is operating in a safe mode.

FIG. 11 is a sectional view of the gate valve in the open position afterthe automatic operation of the actuator, the mechanical override havingbeen partially actuated, and the safe mode indicator indicating that thegate valve is not operating in the safe mode.

FIG. 12 is a cross-sectional view of the mechanical override alongsection line 12-12 in FIG. 11.

FIGS. 13A-13C illustrate a safe mode indicator according to oneembodiment.

DETAILED DESCRIPTION

FIG. 1 is a sectional view of a mechanical override 100, an actuator101, a gate valve 102, and a safe mode indicator 103. The actuator 101couples to a valve body 104 of the gate valve 102. A bonnet assembly canprovide an interface between the gate valve 102 and the actuator 101.During an automatic operation of the gate valve 102, hydraulic orpneumatic pressure enters a chamber 106 of the actuator 101 defined by acover 108 of the actuator 101 and a diaphragm 110 positioned over anoperator member 112. The operator member 112 moves in response to thehydraulic or pneumatic pressure within the chamber 106 and against abiasing force supplied by a spring 118. A valve stem 114 coupled to asliding gate 116 of the gate valve 102 moves in response to the movementof the operator member 112. In this manner, the automatic operation ofthe actuator 101 moves the sliding gate 116 of the gate valve 102between a closed position shown in FIG. 1 and an open position as shownin FIG. 3.

In one embodiment, the actuator 101 may be selected from the pneumaticand hydraulic actuators described in detail in U.S. Pat. No. 6,450,477which is herein incorporated by reference in its entirety. The actuator101 may be selected from any other actuator known in the industry formoving the sliding gate 116 of the gate valve 102 between the open andclosed positions by automatic operation.

When using the automatic operation of the actuator 101, the biasingforce of the spring 118 is configured to act as a fail-safe mechanism.When the pressure in the actuator 101 is removed, inadvertently orotherwise, the spring 118 will move the gate valve 102 into a fail-safeclosed position illustrated in FIG. 1. Although the mechanical override100 may provide an additional means to actuate the gate valve 102 in theevent of a failure, such as a loss of pressure, it may also override thefail-safe mechanism. The mechanical override 100 may prevent the spring118 from moving the gate valve 102 into the fail-safe closed position.The gate valve 102 is operating in a safe mode when the fail-safemechanism has not been overridden by the mechanical override and is notprevented or inhibited from moving into the fail-safe closed position.Therefore, the safe mode indicator 103 is configured to provide asignal, such as a visual indication, communicating to a valve operatorthat the valve is or is not operating in the safe mode. The signal fromthe safe mode indicator 103 may also communicate that (1) the valve willmove to the fail-safe closed position in the event of a pressure loss inthe actuator, (2) the valve has been automatically actuated into theopen position, and/or (3) the mechanical override will not disable orinterfere with the fail-safe mechanism.

As illustrated in FIG. 1, the mechanical override 100 is connected tothe actuator 101 to provide a manual operation for moving the slidinggate 116 between open and closed positions. The mechanical override 100includes a top shaft 160, a lever for manual rotation of the top shaft160, such as a handwheel 200, a housing 150 having a longitudinal boretherethrough, a drive sleeve 204 rotationally locked to the housing 150,and a top seal cartridge 250. The housing 150 passes through an aperture152 in the cover 108 of the actuator 101. A shoulder 154 formed by aportion of the housing 150 with an increased outer diameter provides astop for positioning the housing 150 in the aperture 152 of the cover108. The housing 150 may be secured to the cover 108 by any known meanssuch as a thread or by welding.

The housing 150 includes an upper bore 209, an inner shoulder 211, a topbore 210, and a bottom bore 212. The inner shoulder 211 is disposedbelow the upper bore 209, the top bore 210 is disposed below the innershoulder 211, and the bottom bore 212 is disposed below the top bore210. The bottom bore 212 has an inner diameter greater than the top bore210. A tapered shoulder 215 is located at the interface between the topbore 210 and the bottom bore 212.

The top seal cartridge 250 is disposed in the upper bore 209 and can beremoved for replacement as a single unit without disassembling theactuator 101 or the mechanical override 100. The top seal cartridge 250is preferably formed of a plastic-like material such as Delrin and isheld in place by at least one retainer ring 252 which is preferablystainless steel. Accessibility to the retainer ring 252 withoutdisassembly of the actuator 101 permits removal of the retainer ring 252from the top of the housing 150, thereby allowing removal andreplacement of the top seal cartridge 250. The top seal cartridge 250contains dual reciprocating top shaft seals 256 and dual static seals258 to ensure seal integrity and long life. The top seal cartridge 250incorporates rod wiper 254 to keep a shaft sealing region therebelowclean of dirt, grease, and other contaminants for longer life of the topshaft seals 256. The rod wiper 254 is preferably made from Molythane 90elastomer. These and other seals may be T-seals or other substantiallyelastomeric seals, such as O-ring seals.

The top shaft 160 extends through the longitudinal bore of the housing150, the top seal cartridge 250, and the drive sleeve 204. The innerdiameter of the inner shoulder 211 is greater than the outer diameter ofthe top shaft 160, but smaller than the outer diameter of the drivesleeve 204. The inner shoulder 211 permits axial movement of the topshaft 160 therethrough while providing a backstop for the drive sleeve204. The top shaft 160 may also include a shoulder configured to engagean upper shoulder of the drive sleeve 204 to prevent removal of the topshaft 160 from the upper end of the drive sleeve 204.

The drive sleeve 204 is disposed in the housing 150 and is movablewithin the top bore 210 and the bottom bore 212. The drive sleeve 204includes a threaded bore 216 that corresponds with a drive thread 214 onan outside surface of the top shaft 160. In one embodiment, the drivethread 214 is an Acme thread capable of functioning under loads andincludes a small number of threads per inch, such as five, in order todecrease the work required to manually operate the actuator 101. Thedrive thread 214 permits unassisted rotation of the top shaft 160 withthe handwheel 200. The threaded engagement permits relative axialmovement between the top shaft 160 and the drive sleeve 204 within thehousing 150. The outer diameter of the upper portion of the drive sleeve204 is substantially the same as the inner diameter of the top bore 210of the housing 150. One or more seals 218, such as o-rings, are providedon the outer diameter of the upper portion of the drive sleeve 204 toform a sealed engagement with the top bore 210 of the housing 150. Oneor more seals 219, such as o-rings, are provided on the inner diameterof the upper portion of the drive sleeve 204 to form a sealed engagementwith the top shaft 160.

In one embodiment, the lower end of the drive sleeve 204 is configuredto move axially relative to the bottom bore 212 of the housing 150 whilebeing rotationally locked relative to the housing 150. Any knownrotational locking assembly that prevents rotation of the drive sleeve204 while permitting the drive sleeve 204 (and the top shaft 160) tomove axially within the housing 150 during the automatic operation ofthe actuator 101 may be used. FIG. 5 illustrates a new rotationallocking assembly by showing one embodiment of a cross-section atsectional line 5-5 in FIG. 1. FIG. 5 illustrates the outer diameter ofthe lower end of the drive sleeve 204 having an oval shape thatcorresponds to an oval shape of the inner diameter of the housing 150.The oval shaped diameters provide a physical interference thatrotationally locks the drive sleeve 204 to the housing 150 withoutinhibiting axial movement of the drive sleeve 204 relative to thehousing 150. The outer diameter of the drive sleeve 204 and the bore ofthe housing 150 may be formed in a number of ways known by one ofordinary skill in the art to prevent relative rotational movement whilepermitting relative axial movement. In one embodiment, the lower portionof the drive sleeve 204 may have one or more splines that extend intoone or more corresponding longitudinal grooves formed in the bottom bore212 of the housing 150 to permit relative axial movement but preventrelative rotational movement. In one embodiment, the lower portion ofthe drive sleeve 204 may be keyed to the bottom bore 212 with a pin thatextends through corresponding longitudinal grooves in the drive sleeve204 and the bottom bore 212.

A coupling assembly 158 prevents longitudinal separation between aretaining nut 162 secured to the operator member 112 and the top shaft160 while isolating rotational movement of the top shaft 160 from theactuator 101 and the gate valve 102. The coupling assembly 158 includesa female coupler 164 and ball bearings 168. The lower end of the topshaft 160 rotates around the upper end of the retaining nut 162 andagainst the ball bearings 168. A bottom shoulder 172 on the top shaft160 is secured against the ball bearings 168, which are positioned onthe upper end of the retaining nut 162, by the female coupler 164. Thefemale coupler 164 is connected to the upper end of the retaining nut162 and includes an upper shoulder that engages the bottom shoulder 172of the top shaft 160 to prevent separation of the shaft from theretaining nut 162 and thus the actuator 101 and the gate valve 102. Thetop shaft 160 freely rotates relative to the retaining nut 162 andeliminates the transmission of torque to the valve stem 114, the slidinggate 116, and/or components of the actuator 101 when using themechanical override 100.

Embodiments of the invention do not require the coupling assemblyconnecting the top shaft 160 with the operator member 112. The top shaft160 of the mechanical override 100 may contact and apply force directlyto a portion of the actuator 101, such as the retaining nut 162 or theoperator member 112 depending on the type of actuator used. For example,the end of the top shaft 160 may directly contact the upper end of theretaining nut 162. The solid retaining nut 162 may include a separatelocking device to prevent the retaining nut 162 from unthreading fromthe operator member 112 since the top shaft 160 rotates during themanual operation of the mechanical override 100. Alternatively, otherknown rotation isolation means may be provided to prevent transferenceof the rotation of the top shaft 160 to other components within theactuator 101 and the gate valve 102.

Referring to FIG. 3, a chamber 310 is formed within the housing 150between the top seal cartridge 250 and the drive sleeve 204. The chamber310 is sealed at an upper end by the engagement between the top sealcartridge 250, the upper bore 209, and the top shaft 160, and at a lowerend by the engagement between the drive sleeve 204, the top bore 210,and the top shaft 160. Fluid communication may be established betweenthe chamber 310 and the actuator 101 when the drive sleeve 204 is movedinto the bottom bore 212, as shown in FIG. 3. In particular, the seals218 of the drive sleeve 204 are moved across the tapered shoulder 215into the bottom bore 212, thereby releasing the sealed engagement withthe top bore 210. When the drive sleeve 204 is located in the bottombore 212 and fluid communication is established between the chamber 310and the actuator 101, the gate valve 102 is operating in the safe mode.When the gate valve 102 is operating in the safe mode, the valve may bemoved to the fail-safe closed position (shown in FIG. 1) by thefail-safe mechanism without interference from the mechanical override100.

The safe mode indicator 103 communicates to a valve operator when thevalve is operating in the safe mode. The safe mode indicator 103includes an indication device 300, such as a sensor, that is connectedto the housing 150. The indication device 300 is in fluid communicationwith the chamber 310 via an orifice 315 located through the housing 150.The pressure in the chamber 310 may be used to actuate the indicationdevice 300 to communication a signal to the valve operator.

In one embodiment, when the chamber 310 is at a first pressure, theindication device 300 may communicate a first signal to the valveoperator to indicate that the valve is not operating in the safe mode.When the chamber 310 is at a second pressure that is different than thefirst pressure, the indication device 300 may communicate a secondsignal that is different than the first signal to the valve operator toindicate that the valve is operating in the safe mode. The pressure inthe chamber 310 may be the pressure directed into the actuator 101 whenfluid communication is established between the chamber 310 and theactuator 101, as shown in FIG. 3. The pressure in the chamber 310 iscommunicated to the indication device 300 through the orifice 315 toactuate the indication device 300. In one embodiment, the first and/orsecond pressures may be in a range from about 0 PSI to about 80 PSI, 150PSI, or greater. In one embodiment, the first and/or second signals maybe a visual indication, such as a colored light or marker, an auditoryindication, an electrical indication or signal, and any other type ofsignal known to one of ordinary skill.

In one embodiment, the indication device 300 may be any commercialsensor, such as a pressure sensor, that can be used to indicate apressure change in the chamber 310. In one embodiment, the indicationdevice 300 may be a Rotowink Indicator, commercially available throughNorgen Ltd. The Rotowink Indicator is a spring-loaded device actuated byair pressure for use in visual monitoring of pneumatic or fluidiccircuits. The device uses two contrasting colors (e.g. black, red,yellow, green) on a rotating ball that can be viewed from any angle toindicate the presence or absence of pressure.

The operation of the invention illustrated in FIGS. 1, 2, 3, and 4 willnow be described. FIG. 1 illustrates the gate valve 102 in the fail-safeclosed position. The spring 118 provides a force configured to bias thevalve stem 114, the operator member 112, the top shaft 160, and thedrive sleeve 204 in an upward direction, thereby positioning the slidinggate 116 in the closed position. Seating of the sliding gate 116 in theclosed position limits the upward axial movement of the top shaft 160and the drive sleeve 204. The mechanical override 100 is in anun-actuated position and does not interfere with the closing of the gatevalve 102. The bias of the spring 118 raises the top shaft 160 to anextended position providing a visual indication that the gate valve 102is in the closed position. The safe mode indicator 103 may provide afirst visual indication that the gate valve 102 is not automaticallyactuated into the operating safe mode and/or the chamber 310 is notpressurized or has experienced a pressure change.

FIG. 2 illustrates the gate valve 102 in an open position after a manualoperation the actuator 101 using the mechanical override 100. To movethe sliding gate 116 to the open position using the mechanical override100, the valve operator manually turns the handwheel 200 to providerotation to the top shaft 160. Rotation of the handwheel 200 rotates thetop shaft 160 to advance the top shaft 160 through the drive sleeve 204across the length of the drive thread 214. As the top shaft 160 rotates,the top shaft 160 advances through the drive sleeve 204 until the upperportion of the drive thread 214 is located at the lower portion of thethreaded bore 216 of the drive sleeve 204. During the manual operation,the inner shoulder 211 provides the backstop that prevents the drivesleeve 204 from moving relative to the housing 150. The manual rotationof the handwheel 200 mechanically advances the top shaft 160 through thehousing 150 to either directly or indirectly axially move the valve stem114 to place the gate valve 102 in the open position. The top shaft 160is mechanically driven against the bias of the spring 118, therebycompressing the spring 118. The top shaft 160 lowers during the manualoperation to a retracted position and provides a visual indication thatthe gate valve 102 is in the open position. The valve operator may alsocheck the safe mode indicator 103 to determine whether the gate valve102 is operating in the safe mode. The pressure in the chamber 310should not have significantly changed during the operation of the gatevalve 102 from the fail-safe closed position, shown in FIG. 1, to theopen position by manual operation, shown in FIG. 2. Thus, the safe modeindicator 103 communicates the same first visual indication to the valveoperator, which has not changed by the mechanical operation of the gatevalve 102. The safe mode indicator 103 may therefore indicate that thegate valve 102 is not operating in the safe mode, has not beenautomatically actuated, has been actuated (at least partially) using themechanical override 100, and/or may be prevented from moving into thefail-safe closed position.

FIG. 3 illustrates the gate valve 102 in the open position after anautomatic operation of the actuator 101. Pressure is directed into thechamber 106 of the actuator 101 to overcome the bias of spring 118 andadvance the top shaft 160, the drive sleeve 204, the operator member112, and the valve stem 114 in a downward direction to position thesliding gate 116 into the open position. The top shaft 160 and the drivesleeve 204 are moved together axially within the bore of the housing 150until the seals 218 on the drive sleeve 204 are moved across the taperedshoulder 215 and into the bottom bore 212. Fluid communication isestablished between the chamber 310 and the chamber 106. The pressure inthe chamber 106 is communicated to the indication device 300 via theorifice 315, thereby actuating the indication device 300. The pressurechange in the chamber 310 actuates the safe mode indicator 103 tocommunicate a second visual indication that is different than the firstvisual indication. Since the top shaft 160 also lowers during theautomatic operation to the retracted position and provides a visualindication that the gate valve 102 is in the open position, the valveoperator may use the safe mode indicator 103 to determine whether thegate valve 102 is operating in the safe mode. The second visualindication may therefore indicate that the gate valve 102 is operatingin the safe mode, has not been mechanically actuated, has beenautomatically actuated, and/or will move into the fail-safe closedposition upon release of pressure in the actuator 101. When operating inthe safe mode, the upper end of the drive sleeve 204 is located at leasta distance X from the inner shoulder 211 of the housing 150. In thisposition, the mechanical override 100 will not disable or interfere withthe fail safe mechanism. When the pressure in the actuator 101 isreleased, the drive sleeve 204 is located a sufficient distance from theinner shoulder 211 so as not to limit upward axial movement of the topshaft 160 and thus the valve stem 114 and the sliding gate 116. In thismanner, the sliding gate 116 may move into the fail-safe closedposition.

FIG. 4 illustrates the gate valve 102 in an open position after anautomatic operation of the actuator 101 and a partial operation of themechanical override 100. Before and/or after automatic actuation of thegate valve 102, the mechanical override 100 may be actuated at leastpartially, inadvertently or otherwise. If the handwheel 200 has beenrotated one or more times, the top shaft 160 and the drive sleeve 204will move relative to each other in an offset position illustrated inFIG. 4. When in the offset position and if the valve is automaticallyactuated, then the upper end of the drive sleeve 204 may be positioned adistance Y from the inner shoulder 211, which would prevent the gatevalve 102 from moving to the fail-safe closed position. In oneembodiment, the distance Y may be any distance that is less than thedistance X identified in FIG. 3. When the pressure in the actuator 101is released, the upper end of the drive sleeve 204 would backstop on theinner shoulder 211 before the sliding gate 116 closes, and limit theupward axial movement necessary to move the sliding gate 116 into thefail-safe closed position. Depending on the amount of offset between thedrive sleeve 204 and the top shaft 160, the sliding gate 116 may belocated in a partially open/closed position. Also, when in the gatevalve 102 is automatically actuated and the drive sleeve 204 is locatedthe distance Y from the inner shoulder 211, the chamber 310 remainsisolated from fluid communication with the chamber 106 by the seals 218and 219. Any slight actuation of the mechanical override 100 may offsetthe top shaft 160 and the drive sleeve 204 enough to prevent the seals218 from moving across the tapered shoulder 215 during automaticactuation.

Since the top shaft 160 may still visually indicate that the valve 102is in the open position in FIG. 4, the valve operator may also check thesafe mode indicator 103 to determine whether the gate valve 102 isoperating in the safe mode. The pressure in the chamber 310 should nothave significantly changed since it is isolated from the chamber 106 bythe seals 218 and 219. Thus, the safe mode indicator 103 communicatesthe same first visual indication to the valve operator, which has notchanged by the automatic actuation of the gate valve 102. The safe modeindicator 103 may therefore indicate that the gate valve 102 is notoperating in the safe mode, has been actuated (at least partially) usingthe mechanical override 100, and/or may be prevented from moving intothe fail-safe closed position. While the actuator 101 is pressurized,the valve operator may rotate the handwheel 200 to advance the drivesleeve 204 into the bottom bore 212 until the gate valve 102 isoperating in the safe mode. The valve operator may rotate the handwheeluntil the safe mode indicator 103 changes from the first visualindication to the second visual indication, e.g. when fluidcommunication is established between the chamber 106 and the chamber310, to ensure that the gate valve 102 is operating in the safe mode.Alternatively, the valve operator may release the pressure in theactuator 101 to permit the drive sleeve 204 to backstop against theinner shoulder 211, and then rotate the handwheel to move the mechanicaloverride 100 into the un-actuated position so that the top shaft 160 andthe drive sleeve 204 are not in an offset position as described above.The actuator 101 may be re-actuated automatically so that the safe modeindicator 103 indicates that the valve is operating in the safe mode.

FIG. 6 illustrates the gate valve 102 in an open position after anautomatic operation of the actuator 101 according to one embodiment. Thegate valve 102, the actuator 101, and the mechanical override 100illustrated in FIG. 6 may each include the embodiments described abovewith respect to FIGS. 1-5. FIG. 6 further illustrates a bore 162disposed through the top shaft 160, a check valve 164 disposed in alower end of the top shaft 160 and in communication with the bore 162,and a retaining member 166 coupled to the top shaft 160 to support thecheck valve 164 in the lower end of the top shaft 160. In oneembodiment, the bore 162 may be disposed through the top shaft 160 inany manner known by one of ordinary skill in the art to allow fluidcommunication between the chamber 310 and the chamber 106. In oneembodiment, the check valve 164 may be any type of valve known by one ofordinary skill in the art, such as a one-way valve, that is operable tocontrol the flow of fluid through the bore 162 in either direction. Inone embodiment, the retaining member 166 may be any type of member knownby one of ordinary skill in the art, such as a retainer ring, that isoperable to maintain the check valve 162 in engagement with the topshaft 160 and/or the bore 162. The top shaft 160 illustrated in FIG. 6may be used in any of the embodiments described with respect to FIG.1-5.

In operation, the bore 162 may be configured to relieve any fluidpressure that is located in the chamber 310, which may cause a pressurelock and prevent the fail-safe mechanism from closing the gate valve102. For example, when the gate valve 102 is operating in the safe modeas illustrated in FIG. 6, the chamber 310 is in fluid communication withthe chamber 106 of the actuator 101 and is filled with pressurizedfluid. As the pressure in the chamber 106 is reduced, the spring 118begins to move the gate valve 102 into the closed position, asillustrated in FIG. 1, and the chamber 310 is sealed upon engagement ofthe seals 218 with the inner surface of the top bore 210. Any fluid thatmay be retained in the chamber 310 is relieved through the bore 162 intothe chamber 106. In one embodiment, the fluid may be forced through thebore 162 and the check valve 164 under its own pressure and/or as it ispressurized as the volume of the chamber 310 is reduced by movement ofthe drive sleeve 204 toward the shoulder 211 via the spring 118. Thecheck valve 164 may allow fluid to flow from the upper end of the topshaft 160, through the bore 162 and into the chamber 106, and preventfluid from flowing into the bore 162 and thus into the chamber 310 fromthe lower end of the top shaft 160. In one embodiment, the top shaft 160may include one or more ports 168 located adjacent to the outlet of thecheck valve 164 to assist with venting fluid pressure into the chamber106. In one embodiment, one or more seals 219 may be situated betweenthe top shaft 160 and the drive member 204 to prevent any unintendedleak paths from communicating fluid to the bore 162 during operation ofthe gate valve 102.

FIGS. 7A and 7B illustrate a safe mode indicator 400 for use with theembodiments described herein. The safe mode indicator 400 is similar tothe indicator 103 and is operable to indicate whether the valve 102and/or actuator 101 are operating in a safe mode. The safe modeindicator 400 may communicate that (1) the valve will move to thefail-safe closed position in the event of a pressure loss in theactuator, (2) the valve has been automatically actuated into the openposition, and/or (3) the mechanical override will not disable orinterfere with the fail-safe mechanism.

The safe mode indicator 400 includes an indication device 410, a housing420, a piston 430, a biasing member 440, a plug member 450, and a ballmember 460. The safe mode indicator 400 is operable as an indicationmechanism as described herein, and/or is generally operable as athree-way, two-position valve mechanism. In particular, a force isapplied to the ball member 460 sufficient to move the piston 430 to aclosed position against the bias of the biasing member 440, therebyclosing fluid communication between port 437 and an opening 421 in theend of the housing 420 adjacent to the ball member 460. When in theclosed position the port 437 is in fluid communication with port 439.When no force or a force less than the biasing force of the biasingmember 440 is applied to the ball member 460, the biasing member 440will move the piston 430 to an open position where fluid communicationis established between the opening 421 and the port 437. When in theclosed position the port 437 is not in fluid communication with port439.

The indication device 410 may be the same as the indication device 300described above. The indication device 410 is operable to provide asignal or other indication when it measures or senses a predeterminedamount of pressure or change in pressure. The signal or indication maybe communicated to a valve operator by any number of ways known in theart, including visual, auditory, and/or electronic communication. In oneembodiment, the indication device 410 may be a pressure sensor. Theindication device 410 is coupled to the housing 420, such as by athreaded engagement, so that it is in fluid communication with a bore425 of the housing 420 via the port 437.

The housing 420 may be a tubular, round, or hexagonally shaped memberwith the bore 425 disposed through the body of the housing 420, and maybe formed from metallic materials, such as stainless steel, aluminum, orother similar materials. The ball member 460, the piston 430, and thebiasing member 440 may be disposed in the bore 425 through an end of thehousing 420, which is closed and sealed with the plug member 450 andseal member 416. The plug member 450 may be threadedly coupled to theend of the housing 420. The ball member 460 may be of sufficientdiameter such that a portion of the ball member 460 extends out of theopening 421 of the housing 420 but cannot fit entirely through opening421. Inner edges of the opening 421 may be tapered to engage the outersurface of the ball member 460 and prevent removal of the ball member460 through the opening 421. Although shown in the form of a sphericalmember, the ball member 460 may include other shaped members configuredto transmit a force to the piston 430 as described herein. Other contactmembers, such as the ball member 460, that are easily replaceable wearmay be used to move or transmit a force to the piston 430, including butnot limited to a pin member, a lever, a button, a switch, a cam member,a piston member, a valve member, a piloted or air valve, and/or othermechanically, hydraulically, pneumatically, and/or electrically operatedcontact members. In one embodiment, instead of the ball member 460, aportion of the piston 430, such as an enlarged end portion of the piston430, may extend through the opening 421 of the housing 420 for contactwith the drive sleeve 204 as further described herein.

The opposite portion of the ball member 460 engages an end of the piston430. The piston 430 may include a tubular, round, or hexagonally shapedmember having a bore 435 disposed through the body of the piston 430.The opposite end of the piston 430 may include a shoulder for supportingand contacting the biasing member 440, which is disposed between thepiston 430 and the plug member 450. The biasing member 440 may include aspring or other similar biasing mechanism to force the piston 430 andthe ball member 460 in one direction toward the opening 421 of thehousing. One or more seal members 412, 413, 414 are disposed on theouter surface of the piston 430, and sealingly engage the inner surfaceof the bore 425. The seal members 412, 413, 414 may be disposed inrecesses or shoulder portions formed on the outer surface of the piston430. In one embodiment, one or more of the seal members 412, 413, 414may be supported by the inner surface of the housing 420 and in sealingengagement with the piston 430, which may be movable relative to theseal members to open and close fluid communication to the ports 437,439. For example, one or more of the seal members 412, 413, 414 may bestatically supported within one or more recesses in the inner surface ofthe housing 420 such that they sealingly engage the piston 430, and thepiston 430 may include one or more recess in its outer surface that aremoved relative to the seal members to bypass one or more of the sealmembers as the piston 430 is moved by the ball member 460 and thebiasing member 440.

When the safe mode indicator 400 is in the open position, as illustratedin FIG. 7A, the piston 430 and thus the seal member 412 is moved withinor past a tapered surface 433 or area of the bore 425 to open fluidcommunication between the opening 421 of the housing 420 and the port437, effectively bypassing the seal member 412. Fluid pressure thus maybe communicated to the indication device 410 via the opening 421 of thehousing 420. When in the open position, seal member 413 seals againstthe inner surface of the bore 425 and prevents fluid communication toport 439. A slot 431 is formed in the end of the piston 430 to allowuninhibited fluid communication through bore 435 to the opposite end ofthe piston 430. The bore 435 is operable equalize fluid pressure orprevent significant pressure differentials across the piston 430 withinthe bore 425. Seal member 414 prevents fluid communication to ports 437,439 from the opposite end of the piston 430.

When the safe mode indicator 400 is in the open position, as illustratedin FIG. 7A, the piston 430 and thus the seal member 412 is moved past atapered surface 433 or other increase in the inner diameter of the bore425 to create a bypass around the seal member 412 and open fluidcommunication between the opening 421 of the housing 420 and the port437. When in the open position, seal member 413 prevents fluidcommunication to port 439.

When the safe mode indicator 400 is in the closed position, asillustrated in FIG. 7B, the piston 430 and thus the seal member 412 ismoved into a reduced inner surface portion of the bore 425 relative tothe tapered surface 433 so that the seal member 412 sealingly engagesthe inner surface and closes fluid communication between the opening 421of the housing 420 and the port 437. When in the closed position, sealmember 413 is moved to the opposite side of the port 439 to thereby openfluid communication between ports 437 and 439. Port 439 may be disposedthrough the body of the housing 420 to communicate with the atmospheresurrounding the safe mode indicator 400. Any pressure within the port437 and the area between seal members 412, 413 may be exhausted toatmosphere via port 439.

The operation of the safe mode indicator 400 with the mechanicaloverride 100, the gate valve 102, and the actuator 101 is illustrated inFIGS. 8, 9, 10, and 11. The mechanical override 100, the gate valve 102,and the actuator 101 are substantially similar as described above withrespect to FIGS. 1-6, and the similar components are identified with thesame reference numerals. The main differences are the use of the safemode indicator 400, the housing 150 having a substantially uniform innerdiameter and/or not requiring the tapered inner shoulder 215 as shown inFIGS. 3 and 4 for example, and the drive sleeve 204 having asubstantially uniform outer diameter and/or not requiring seal 218disposed on its outer diameter, also as shown at least in FIGS. 3 and 4for example.

As illustrated in FIG. 8, the safe mode indicator 400 is coupled to thehousing 150. In particular, a connector portion 425 (see FIGS. 7A&B) ofthe safe mode indicator 400 may be threadedly coupled to the housing150, and a seal member 411 (see FIGS. 7A&B) may provide a sealedengagement between the safe mode indicator 400 and the housing 150. Thesafe mode indicator 400 may be coupled to the housing 150 so that aportion of the ball member 460 extends into the chamber 310 of thehousing 150 such that it may contact the drive sleeve 204. The opening421 of the housing 420 of the safe mode indicator 400 is also in fluidcommunication with the chamber 310 of the housing 150 within which thedrive sleeve 204 is located. In this manner, as the drive sleeve 204moves axially within the housing 150, it will contact and be moved fromcontact with the ball member 460, thereby moving the safe mode indicator400 into the open and closed positions.

When contacting the outer surface of the drive sleeve 204, the ballmember 260 and the piston 430 are forced in one direction into thehousing 420 (and away from housing 150) against the bias of the biasingmember 440. The seal member 412 is moved toward the tapered surface 433and into sealing engagement with the inner surface of the bore 425 toisolate fluid communication to port 437 and the indication device 410.The safe mode indicator 400 is in the closed position, and theindication device is in fluid communication with the atmosphere and maysense or measure the pressure in the atmosphere via ports 437 and 439.When in the closed positi on, the indication device 410 may communicatea signal or other indication that the actuator 101 and the valve 102 areclosed and/or are not operating in the safe mode.

When not contacting the outer surface of the drive sleeve 204, the ballmember 260 and the piston 430 are forced toward the housing 150 by thebiasing member 440. The seal member 412 is moved out of the taperedsurface 433 and removed from sealing engagement with the inner surfaceof the bore 425 to open fluid communication to port 437 and theindication device 410. The safe mode indicator 400 is in the openposition, and the indication device 410 is in fluid communication withthe chamber 310 and thus chamber 106, and may sense or measure thepressure or change in pressure in the chambers 310, 106 via the opening421, the bore 425, and the port 437. The ball member 460 may bepositioned and movable within the pressurized environment but does notcreate any seals to prevent fluid communication between the chambers310, 106 and the bore 425 of the housing 150. When in the open position,the indication device 410 may communicate a signal or other indicationthat the actuator 101 and the valve 102 are open and/or are operating inthe safe mode.

The operation of the mechanical override 100, the actuator 101, the gatevalve 102, and the safe mode indicator 400 will now be described withreference to FIGS. 8-11. FIG. 8 illustrates the gate valve 102 in thefail-safe closed position. The spring 118 provides a force configured tobias the valve stem 114, the operator member 112, the top shaft 160, andthe drive sleeve 204 in an upward direction, thereby positioning thesliding gate 116 in the closed position. Seating of the sliding gate 116in the closed position limits the upward axial movement of the top shaft160 and the drive sleeve 204. The mechanical override 100 is in anun-actuated position and does not interfere with the closing of the gatevalve 102. The bias of the spring 118 raises the top shaft 160 to anextended position providing a visual indication that the gate valve 102is in the closed position. The drive sleeve 204 is adjacent to andcontacting the ball member 460, which forces the safe mode indicator 400into the closed position such that it is in fluid communication withatmospheric pressure. The safe mode indicator 400 may provide a firstvisual indication that the gate valve 102 is not automatically actuatedinto the operating safe mode.

FIG. 9 illustrates the gate valve 102 in an open position after a manualoperation the actuator 101 using the mechanical override 100. To movethe sliding gate 116 to the open position using the mechanical override100, the valve operator manually turns the handwheel 200 to providerotation to the top shaft 160. Rotation of the handwheel 200 rotates thetop shaft 160 to advance the top shaft 160 through the drive sleeve 204across the length of the drive thread 214. As the top shaft 160 rotates,the top shaft 160 advances through the drive sleeve 204 until the upperportion of the drive thread 214 is located at the lower portion of thethreaded bore 216 of the drive sleeve 204. During the manual operation,the inner shoulder 211 provides the backstop that prevents the drivesleeve 204 from moving relative to the housing 150. The manual rotationof the handwheel 200 mechanically advances the top shaft 160 through thehousing 150 to either directly or indirectly axially move the valve stem114 to place the gate valve 102 in the open position. The top shaft 160is mechanically driven against the bias of the spring 118, therebycompressing the spring 118. The top shaft 160 lowers during the manualoperation to a retracted position and provides a visual indication thatthe gate valve 102 is in the open position. The valve operator may alsocheck the safe mode indicator 400 to determine whether the gate valve102 is operating in the safe mode. Since the drive sleeve 204 has notbeen moved from its contact with the ball member 460, the communicationby indication device 410 should not have changed during the operation ofthe gate valve 102 from the fail-safe closed position, shown in FIG. 1,to the open position by manual operation, shown in FIG. 2. Thus, thesafe mode indicator 400 communicates the same first visual indication tothe valve operator, which has not changed by the mechanical operation ofthe gate valve 102. The safe mode indicator 400 may therefore indicatethat the gate valve 102 is not operating in the safe mode, has not beenautomatically actuated, has been actuated (at least partially) using themechanical override 100, and/or may be prevented from moving into thefail-safe closed position.

FIG. 10 illustrates the gate valve 102 in the open position after anautomatic operation of the actuator 101. Pressure is directed into thechamber 106 of the actuator 101 to overcome the bias of spring 118 andadvance the top shaft 160, the drive sleeve 204, the operator member112, and the valve stem 114 in a downward direction to position thesliding gate 116 into the open position. The top shaft 160 and the drivesleeve 204 are moved together axially within the bore of the housing 150toward the gate valve 102, such that the drive sleeve 204 is moved outof contact with the ball member 460. The biasing member 430 moves thepiston 430, the ball member 460, and the seal member 412 toward thehousing 150. The seal member 412 is moved out of the tapered surface 433area so that it does not sealingly engage the inner bore 425 of thehousing 420. The safe mode indicator 400 is in the open position, andfluid communication is open between the chamber 106, the chamber 310,the bore 425 (via opening 421) and the port 437. The pressure in thechamber 106 may therefore be communicated to the indication device 410to actuate the indication device 410. The pressure may also flow throughthe bore 435 of the piston 430 to equalize the pressure within thehousing 150 and/or prevent any significant pressure differentials acrossthe piston 430 and seal members 412, 413, 414. The pressure change inthe actuator 101 actuates the safe mode indicator 400 or indicationdevice 410 to communicate a second visual indication that is differentthan the first visual indication. Since the top shaft 160 also lowersduring the automatic operation to the retracted position and provides avisual indication that the gate valve 102 is in the open position, thevalve operator may use the safe mode indicator 400 to determine whetherthe gate valve 102 is operating in the safe mode. The second visualindication may therefore indicate that the gate valve 102 is operatingin the safe mode, has not been mechanically actuated, has beenautomatically actuated, and/or will move into the fail-safe closedposition upon release of pressure in the actuator 101. When operating inthe safe mode, the upper end of the drive sleeve 204 is located at leastat or below a distance X from the inner shoulder 211 of the housing 150.In this position, the drive sleeve 204 is located relative to the ballmember 460 so that is does not move the safe mode indicator 400 to theclosed position, and the mechanical override 100 will not disable orinterfere with the fail safe mechanism of the actuator 101. When thepressure in the actuator 101 is released, the drive sleeve 204 islocated a sufficient distance from the inner shoulder 211 so as not tolimit upward axial movement of the top shaft 160 and thus the valve stem114 and the sliding gate 116. In this manner, the sliding gate 116 maymove into the fail-safe closed position.

FIG. 11 illustrates the gate valve 102 in an open position after anautomatic operation of the actuator 101 and a partial operation of themechanical override 100. Before and/or after automatic actuation of thegate valve 102, the mechanical override 100 may be actuated at leastpartially, inadvertently or otherwise. If the handwheel 200 has beenrotated one or more times, the top shaft 160 and the drive sleeve 204will move relative to each other in an offset position illustrated inFIG. 11. When in the offset position and if the valve is automaticallyactuated, then the upper end of the drive sleeve 204 may be positioned adistance Y from the inner shoulder 211, which would prevent the gatevalve 102 from moving to the fail-safe closed position. In oneembodiment, the distance Y may be any distance that is less than thedistance X identified in FIG. 10 such that the drive sleeve 204 engagesthe ball member 460 to move the safe mode indicator 400 into the closedposition. When the pressure in the actuator 101 is released, the upperend of the drive sleeve 204 would backstop on the inner shoulder 211before the sliding gate 116 closes, and limit the upward axial movementnecessary to move the sliding gate 116 into the fail-safe closedposition. Depending on the amount of offset between the drive sleeve 204and the top shaft 160, the sliding gate 116 may be located in apartially open/closed position. Also, when in the gate valve 102 isautomatically actuated and the drive sleeve 204 is located the distanceY from the inner shoulder 211, the chambers 106 and 310 remain isolatedfrom fluid communication with the indication device 410 by the sealmember 412. Any slight actuation of the mechanical override 100 mayoffset the top shaft 160 and the drive sleeve 204 enough to move thesafe mode indicator 400 to the closed position during an automaticactuation of the actuator 101.

Since the top shaft 160 may still visually indicate that the valve 102is in the open position in FIG. 11, the valve operator may also checkthe safe mode indicator 400 to determine whether the gate valve 102 isoperating in the safe mode. The pressure in the chambers 106 and 310 isisolated from the indication device 410 by the seal member 412. Thus,the safe mode indicator 400 communicates the same first visualindication to the valve operator, which may have not changed by theautomatic actuation of the gate valve 102. The safe mode indicator 400may therefore indicate that the gate valve 102 is not operating in thesafe mode, has been actuated (at least partially) using the mechanicaloverride 100, and/or may be prevented from moving into the fail-safeclosed position. While the actuator 101 is pressurized, the valveoperator may rotate the handwheel 200 to advance the drive sleeve 204toward the gate valve 102 and out of contact with the ball member 460 sothat the gate valve 102 is operating in the safe mode. The valveoperator may rotate the handwheel until the safe mode indicator 400changes from the first visual indication to the second visualindication, e.g. when fluid communication is established between thechambers 106, 310 and the indication device 410, to ensure that the gatevalve 102 is operating in the safe mode. Alternatively, the valveoperator may release the pressure in the actuator 101 to permit thedrive sleeve 204 to backstop against the inner shoulder 211, and thenrotate the handwheel to move the mechanical override 100 into theun-actuated position so that the top shaft 160 and the drive sleeve 204are not in an offset position as described above. The actuator 101 maybe re-actuated automatically so that the safe mode indicator 400indicates that the valve is operating in the safe mode.

FIG. 12 illustrates a cross-section at sectional line 12-12 in FIG. 11of a rotational locking assembly. FIG. 12 illustrates the inner diameterof the housing 150 having a spline or key portion 151, which ispositioned within a recess or groove in the outer diameter of the drivesleeve 204 to rotationally lock the housing 150 and the drive sleeve204. In one embodiment, the spline or key portion 151 may be welded tothe inner surface of the housing 150. The splined or keyed engagementprovides a physical interference that rotationally locks the drivesleeve 204 to the housing 150 without inhibiting axial movement of thedrive sleeve 204 relative to the housing 150. The outer diameter of thedrive sleeve 204 and/or the inner diameter of the housing 150 may beformed in any number of ways known by one of ordinary skill in the artto prevent relative rotational movement while permitting relative axialmovement.

FIGS. 13A-13C illustrate a safe mode indicator 500 for use with theembodiments described herein and vice versa. The safe mode indicator 500is similar to the indicators 103, 300, 400 and is operable to indicatewhether the valve 102 and/or actuator 101 are operating in a safe mode.The safe mode indicator 500 may communicate that (1) the valve will moveto the fail-safe closed position in the event of a pressure loss in theactuator, (2) the valve has been automatically actuated into the openposition, and/or (3) the mechanical override will not disable orinterfere with the fail-safe mechanism.

The safe mode indicator 500 includes a housing comprising a firsthousing member 510 coupled to a second housing member 520. In oneembodiment, an outer diameter end of the first housing member 510 may bethreadedly connected to an inner diameter portion of the second housingmember 520, as illustrated by threaded connection 519. One or more setscrews may be disposed through openings 521 in the body of the secondhousing member 520 and into engagement with first housing member 510 toprevent uncoupling of the first and second housing members 510, 520. Thefirst housing member 510 may further include a threaded connection end515 for coupling the safe mode indicator 500 to the housing 150 of themechanical override 100. The second housing member 520 may include oneor more openings 530 disposed through the body of the second housingmember 520 for viewing one or more indicators 580, 590 as furtherdescribed herein.

Enclosed within the safe mode indicator 500 are a contact member (suchas ball member 540), a piston member 550, a plug member 560, a spring(such as biasing member 565), a pin member 570, and indicators 580, 590.The ball member 540, the piston member 550, the plug member 560, and thebiasing member 565 may be fully or at least partially disposed in thebore of the first housing member 510. The ball member 460 may be ofsufficient diameter such that a portion of the ball member 540 mayextend out of the open end 517 of the first housing member 510 butcannot fit entirely through the open end 517. The inner edges of theopen end 517 may be tapered to engage the outer surface of the ballmember 540 and prevent removal of the ball member 540 through the openend 517.

In contact with the ball member 540 is the piston member 550, whichincludes a shoulder portion 555 for engagement with one end of thebiasing member 565. The opposite end of the biasing member 565 engagesthe plug member 560, which is coupled to the end of the first housingmember 510 opposite the open end 517. A portion of the plug member 560may be threadedly coupled to the inner diameter of the bore of the firsthousing member 510 such that a shoulder of the plug member 560 abuts theend of the first housing member 510. A seal member 562 may provide aseal between the first housing member 510 and the plug member 560. Theremaining portion of the piston member 550 may be disposed through thebiasing member 565 and the bore of the plug member 560 for connectionwith the pin member 570, such as by a threaded connection. A seal member561 may provide a seal between the piston member 550 and the plug member560. In one embodiment, the pin member 570 may be a bolt or screw typemember that threads into an end of the piston member 550. The pin member570 may be disposed through the indicators 580, 590, which are securedbetween the piston member 550 and a head or shoulder portion of the pinmember 570. In this manner, movement of the piston member 550 moves thepin member 570 and both the indicators 580, 590 within the bore of thesecond housing member 520 for viewing through the openings 530 of thesecond housing member 520. In one embodiment, the indicators 580, 590may be in the form of a disc or other (circular) member that is easilysecurable and movable within the second housing member 520. Eachindicator 580, 590 may also include a distinctive color or mark toprovide a signal viewable through the openings 530 in the second housingmember 520 corresponding to the position of the safe mode indicator 500and thus the operating condition of the valve 102 and/or actuator 101.Finally, a closure member 525 may be coupled to the end of the secondhousing member 520 to enclose and protect the components therein.

FIG. 13B illustrates the safe mode indicator 500 when indicating thatthe valve 102 and/or actuator 101 are operating in a safe mode. Inparticular, the biasing member 565 biases the piston member 550 towardthe open end 517, which pushes or forces the ball member 540 topartially extend outward of the open end 517 of the first housing member510. The piston member 550 also moves or shifts the pin member 570 andthe indicators 580, 590 relative to the second housing member 520 to aposition where only the indicator 580 is visible through the openings530. The drive sleeve 204 is in the position illustrated in FIG. 10 suchthat is does not contact the ball member 540 and is located at least ator below the distance X from the inner shoulder 211 of the housing 150.In this position, the drive sleeve 204 is located a sufficient distancefrom the inner shoulder 211 so that it will not inhibit fail safeclosure of the valve 102.

When the safe mode indicator 500 is in the position illustrated in FIG.13B, the indicator 580 is displayed through the openings 530. Theindicator 580 may be a certain color, such as a green color, to indicateto an operator or other user that the valve 102 and/or actuator 101 areoperating in a safe mode. The safe mode indicator 500 may continuouslydisplay the indicator 580 until the valve 102 and/or valve actuator 101are moved to a position where they are not operating in the safe mode.

FIG. 13C illustrates the safe mode indicator 500 when indicating thatthe valve 102 and/or actuator 101 are not operating in the safe mode. Inparticular, ball member 540 is moved or forced into the bore of thefirst housing member 510 by contact with the drive sleeve 204. The drivesleeve 204 may be in the position illustrated in FIG. 11 for example orin any other position that is located less than the distance X from theinner shoulder 211 of the housing 150. In this position, the drivesleeve 204 is located a distance from the inner shoulder 211 that willinhibit fail safe closure of the valve 102. The ball member 540 movesthe piston member 550 against the bias of the biasing member 565, whichis compressed between the shoulder 555 of the piston member 550 and theend of the plug member 560. The piston member 550 also moves or shiftsthe pin member 570 and the indicators 580, 590 relative to the secondhousing member 520 to a position where only the indicator 590 is visiblethrough the openings 530. The indicator 590 may be a certain color, suchas a red color, to indicate to an operator or other user that the valve102 and/or actuator 101 are not operating in the safe mode. The safemode indicator 500 may continuously display the indicator 590 until thevalve 102 and/or valve actuator 101 are moved to a position where theyare operating in the safe mode as described above.

The safe mode indicator 500 is not limited to use with the mechanicaloverride 100, the actuator 101, and/or the valve 102 described herein,but may be used with similar and/or other types of overrides, actuators,and/or valves. For example, the safe mode indicator 500 may be used withmechanical override systems that are sealed from fluid pressure. In oneexample, the safe mode indicator 500 may be coupled to an outer housingof a mechanical override system such that a drive sleeve of themechanical override is movable into and out of contact with the ballmember 540, thereby actuating the indicator 500 as described above. Theouter housing of the mechanical override may be coupled to a housing ofan actuator, such as by a threaded or welded connection, but may besealed from fluid communication with the actuator. In one embodiment,the safe mode indicator 500 is a purely mechanically operated systemthat does not rely on any hydraulic, pneumatic, and/or electric powersupply or source. Additional embodiments of the safe mode indicators103, 300, 400 and/or 500, however, may include one or a combination ofmechanical, fluid, electric powered type systems.

In one embodiment, the top shaft 160 may be provided with a mark (orother similar type of indication, such as a notch in the outer diameter)located along its length such that the mark is visible only when thevalve 102, the actuator 101, and/or the mechanical override 100 are in afully closed position. For example, a mark may be provided on the outerdiameter of the top shaft 160 that is visible slightly above the housing150 when the top shaft 160 is in the position illustrated in FIG. 1 orin a fully extended position. In FIG. 1, the valve 102 is in the fullyclosed position. An operator or other user may view the mark as anindication that the valve 102 is in the fully closed position. Movementof the top shaft 160 into the housing 150 will also move the mark intothe housing 150 an out of view from the operator or user. When the markis not visible, the operator or user may use this as an indication thatthe valve 102 is not in the fully closed position. The mark on the topshaft 160 may be used alone or in combination with the other embodimentsdescribed herein to determine the operational state of the valve 102,the actuator 101, and/or the mechanical override 100.

While the foregoing is directed to embodiments of the invention, otherand further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

The invention claimed is:
 1. An indicator apparatus, comprising: ahousing having a bore disposed therethrough; a piston movable within thehousing; a biasing member operable to move the piston to a firstposition; a contact member operable to move the piston to a secondposition against the bias of the biasing member; and an indicatorcoupled to the piston, wherein the indicator provides a signal viewablethrough an opening in the housing when the piston is moved to the firstposition and a different signal viewable through the opening when thepiston is moved to the second position, wherein the indicator comprisesa first disc member that provides the signal viewable when the piston isin the first position, and a second disc member that provides thedifferent signal viewable when the piston is in the second position. 2.The apparatus of claim 1, wherein the housing comprises a first housingmember threadedly coupled to an inner diameter portion of a secondhousing member.
 3. The apparatus of claim 1, further comprising a plugmember coupled to the housing, wherein the biasing member is disposedbetween a shoulder of the piston and an end of the plug member.
 4. Theapparatus of claim 1, wherein the biasing member biases the piston intocontact with the contact member, and wherein a portion of the contactmember is disposed outside of the bore of the housing when the piston isin the first position.
 5. The apparatus of claim 1, wherein the contactmember comprises a ball member that is movably disposed within the boreof the housing to move the piston against the bias of the biasingmember.
 6. The apparatus of claim 1, wherein the signal is a color ofthe first disc member, and the different signal is a color of the seconddisc member.
 7. The apparatus of claim 6, wherein the first and seconddisc members are coupled to the piston by a pin member that isthreadedly connected to the piston.
 8. A valve assembly, comprising: avalve; a hydraulic or pneumatic actuator operable to actuate the valveto an open position and a closed position, wherein the actuatorcomprises a fail-safe mechanism operable to move the valve to the closedposition upon loss or release of fluid pressure in the actuator; amechanical override operable to actuate the valve to the open positionand the closed position, wherein actuation of the valve using themechanical override prevents the valve from moving to the closedposition by the fail-safe mechanism; and an indication apparatusoperable to indicate whether the valve is operating in a fail-safe mode,the indication apparatus comprising: a housing having a bore disposedtherethrough; a piston movable within the housing; a biasing memberoperable to move the piston to a first position; a contact memberoperable to move the piston to a second position against the bias of thebiasing member; and an indicator coupled to the piston, wherein theindicator provides a signal viewable through an opening in the housingwhen the piston is moved to the first position and a different signalviewable through the opening when the piston is moved to the secondposition; and wherein a drive sleeve of the mechanical override contactsthe contact member to move the contact member and the piston to thesecond position, and wherein when the piston is in the second position,the signal viewable through the opening in the housing indicates thatthe valve is not operating in the fail-safe mode.
 9. The valve assemblyof claim 8, wherein actuation of the valve using the hydraulic orpneumatic actuator moves the drive sleeve from contact with the contactmember so that the biasing member moves the piston to the firstposition, and wherein when the piston is in the first position, thesignal viewable through the opening in the housing indicates that thevalve is operating in the fail-safe mode.
 10. The valve assembly ofclaim 8, further comprising a shaft coupled to the valve and having amark formed on its outer surface that is only viewable when the valve isin the closed position.
 11. A valve assembly, comprising: a valve; ahydraulic or pneumatic actuator operable to actuate the valve to an openposition and a closed position, wherein the actuator comprises afail-safe mechanism operable to move the valve to the closed positionupon loss or release of fluid pressure in the actuator; a shaft coupledto the valve and having a mark formed on its outer surface that is onlyviewable when the valve is in the closed position; a mechanical overrideoperable to actuate the valve to the open position and the closedposition; and an indication apparatus operable to indicate whether thevalve is operating in a fail-safe mode, the indication apparatuscomprising: a housing having a bore disposed therethrough; a pistonmovable within the housing; a biasing member operable to move the pistonto a first position; a contact member operable to move the piston to asecond position against the bias of the biasing member; and an indicatorcoupled to the piston, wherein the indicator provides a signal viewablethrough an opening in the housing when the piston is moved to the firstposition and a different signal viewable through the opening when thepiston is moved to the second position.